Process for processing cylinder crankcases having sprayed cylinder barrels

ABSTRACT

In a process for processing cylinder crankcases having sprayed cylinder barrels, in which process a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to final dimensions. After the thermal spraying process, coating material is at least partially removed from the crankshaft-side part of the cylinder crankcase.

This application claims the priority of German application 10 2004 038183.6, filed Aug. 6, 2004, the disclosure of which is expresslyincorporated by reference herein.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates to a process for processing cylindercrankcases having sprayed cylinder barrels.

For production of engines with thermally sprayed cylinder bearingsurfaces, it is known from European document EP 1 141 438 B1 to cast,clean and degrease a cylinder crankcase, to roughen the cylinder boresby means of corundum or sand blasting, and then to thermally coat thecylinder bores. The coating and roughening operations use a templatewhich covers cylinder bores which are not to be processed at that timeand may have exchangeable consumable layers on the inner side. After thecoating operation, the cylinder crankcase is machined to its finaldimensions.

Despite the advantages of this process, in particular the bonding of thesprayed layer which subsequently forms the cylinder bearing surface isin need of improvement. Furthermore, the outlay on equipment is veryhigh. This is also true of the production costs.

One object of this invention is to develop a process which allows goodbonding of the layer to be achieved, while production is as economicalas possible, with as low a scrap rate as possible.

This object is achieved by a process for processing cylinder crankcaseshaving sprayed cylinder barrels in which a cylinder crankcase is cast,those surfaces of the subsequent cylinder barrels which are to bethermally coated are roughened, and the cylinder barrels are remachinedto their final dimensions. The following text describes a process forproducing a cylinder crankcase with thermally sprayed cylinder liners,clearly revealing the advantages attributable to the invention. Thisroute is selected since the advantages in some cases only manifestthemselves at a completely different location. During production, acylinder crankcase is cast. The material used for the cylindercrankcase, which is preferably produced as a shaped casting,particularly preferably as a pressure die casting, is a gray cast ironmaterial or a light metal material, such as an aluminum alloy.

A cast cylinder crankcase according to the invention has an oversizeddimension at least in the region of the cylinder head sealing surfaceand, in the case of a four-cylinder engine, has four cylinder boresarranged in line. The walls of the cylinder bores are provided with abearing surface layer. The bearing surface layer is applied, afterpreprocessing of the cylinder bores or of the cylinder crankcase, by wayof a thermal spraying process and, in particular, a plasma and/or arcwire spraying process.

The materials used here are preferably thermal spraying materials whichare customary for such purposes, preferably Fe-containing materials. Thelayer thickness of the bearing surface layer is usually several hundredmicrometers and, preferably, at least 150 micrometers.

After casting, the cast cylinder crankcase is cleaned and degreased.Then, the surface of the cylinder bores is roughened. It is preferablefor roughening to be carried out by way of a fluid which is blasted ontothe walls at a high pressure (several hundred to several thousand bar).In this case, as in the case, for example, of sand blasting, it is alsopossible for solid particles, such as sand or corundum, to be added tothe blasting fluid. In the present application, processes of this typeare referred to merely as blasting processes or as blasting machining,for the sake of simplicity.

It is preferable to use a particle-free water jet to which 1-5% byvolume of a liquid cleaning agent and/or a liquid preservative has beenadded. The use of the preservative at least reduces the risk of theblasted cylinder crankcase and the device suffering corrosion, with thecleaning agent being used for further or better removal of impurities orresidual coverings, such as center sleeve parting agents used inpressure die casting.

If the blasting machining uses a water jet of this type, it is expedientthat a cylinder crankcase which has been blasted in this manner does notrequire any complex cleaning processes. This is associated, inter alia,with a reduction in overall processing costs, less space being taken upby the machines, and reduced investment costs.

The blast machining which is provided for the purpose of roughening canadvantageously be used not only to roughen the surface to be coated, butalso at the same time to clean and degrease the walls of the cylinderbores. In this case, it is particularly appropriate to use liquidcleaning agent. This, inter alia, reduces a working step and thereforethe machine costs, with a simultaneous associated reduction inprocessing time and costs per item.

Since the hardness may vary along the axial extent of the cylinder bore,it is expedient for the time of action on the wall of the cylinder borewhich is to be machined to be selected in such a manner that, where thehardness of the wall is lowest, the amount of material removed plus theinternal diameter which then remains corresponds at most to thesubsequent final dimension minus the minimum application of materialrequired for the bearing surface layer. In this context, tests haveshown that it is favorable to remove at most between 0.020 and 0.140 mm,preferably between 0.004 mm and 0.006 mm.

In anticipation of the further process, it should also be mentioned inthis context in particular that to improve the subsequent bonding of thesprayed layer to the cylinder crankcase, it is expedient for thecylinder bore—as seen in the direction of the crankshaft—to also beroughened at least slightly (a few mm) beyond the region of thesubsequent cylinder bearing surface on the crankshaft side in the mannerdescribed, and also for it to be cleaned, degreased, and, ifappropriate, machined in a suitable way.

Surprisingly, it has been established that when using a (high-pressure)blasting process, it is expedient for a lance which guides the jet andis directed onto the wall of the cylinder bore to be operated in such amanner that it is for some time activated outside the cylinder bore.This means that it is operated at most at the subsequent workingpressure with the fluid, in particular with water or a fluid providedwith solid particles. Then, the lance is introduced into the cylinderbore, and the walls are covered by the jet and processed in the desiredway.

Of course, to reduce the operating times and therefore also, inter alia,to reduce costs, it is expedient for a plurality of roughening lances tobe used for the roughening and/or the machining by means of blastingand/or the cleaning and degreasing which is expediently carried out inthe process, in particular by the addition of the cleaning agents and/orpreservatives. Surprisingly, it has been established that with thisprocedure it is expedient for these lances to be operated in such amanner that they are activated not only—as mentioned in the case of theuse of a single lance—for a certain time outside the cylinder bore, butalso for the jets which escape in the process to be directed onto abaffle surface. The baffle surface in this case advantageously serves tostabilize the working jet and therefore to improve the reproducibilityof the working results.

In a preferred configuration of the baffle surface in the form of ahollow cylinder, in which the jet outlet for the jet is to be arranged,the lances can, in an improved version, be rotated without problems, asis already the case for covering the walls of the cylinder bores withthe jet. This reduces interference with the two lances by the otherlance in each instance. The baffle surfaces which concentricallysurround the lances are preferably made from a hard metal or reinforcedsteel (e.g. in particular case-hardened steel No. 1.7131 (16MoCr5)), sothat the abrasive action of the jets, which are passed out of the lancesfrom a fan jet nozzle, despite their extremely high pressure, isrelatively slight, and the service life of baffle surfaces of this typeis very long.

The same objective is also served by the use of a single pressure sourcefor the lances which are in use, since in this case identical or similarworking results can be assumed for the cylinder bores which have beenprocessed in each instance. This has a particular influence on the abovementioned machining of the wall of the cylinder bore which issubsequently to be coated.

If a plurality of lances are used for simultaneous processing of aplurality of cylinder bores belonging to a line of cylinders, theselances are expediently not introduced simultaneously into cylinder boreswhich directly follow one another. Instead, at least one cylinder is tobe left clear between the cylinder bores into which the lances areintroduced. This, inter alia, reduces the influence which the lanceshave on one another and the potential threat to the lances, inparticular from their jets. In particular, the guidance of the lances isalso simplified, since the free space between two lances is increased.

In cylinder crankcases with an odd number of cylinder bores, when usinga plurality of jet lances simultaneously, it is expedient for at leastone to be configured such that it can be moved in the axial directionindependently of the other and/or for them to be operated separatelyfrom one another with the blasting fluid, i.e. in particular with water.As a result, by way of example, one of the lances, when it is notarranged in a cylinder bore, can be switched off and/or operated in theregion of the baffle surface and/or remain in an at-rest position, whilethe other blasting lance is applying the jet to one of the cylinderbores.

It is preferable for the cylinder crankcase to be fitted with one ormore hollow-cylindrical baffle surfaces within the blasting machiningunit, specifically in the region in which the blasting lances are alsointroduced into the cylinder bores. It is expedient for the bafflesurfaces in this case to be arranged on a guide, by means of which theycan be lowered onto the cylinder head sealing surface and put or placedand fixed on it in a defined position. For this purpose, the guide forthe baffle surfaces is expediently arranged around a lance, so that thelance can be arranged within the hollow-cylindrical baffle surface andthe baffle surface can be guided concentrically around the lance.

After blast machining, the cylinder crankcase, which may have beenpreprocessed, in particular face-milled, on the cylinder head sealingsurface but still has an oversized dimension of preferably between 0.3and 0.7 mm and particularly preferably between 0.4 and 0.5 mm, isremoved from the blast machining unit. The blast machining unitpreferably has a turntable with at least two receptacles, so thatsimultaneous loading of the machining unit in the region of the lancesand removal and/or loading of a receptacle is possible. Alternatively,this can also be realized by linear drives or other similar customaryproduction tools.

After blast machining, i.e. at least roughening of the walls of thecylinder bores, the cylinder crankcase is tilted. For this purpose, thecylinder crankcase is rotated about a longitudinal axis of a cylinderline, so that an acute angle between the axial axis of a cylinder boreand the field line of the weight is present at least in a rotaryposition which is held at least for a short time. It is preferable forthe cylinder crankcase, starting from the initial position defined bythe cylinder head sealing surface facing upwards, is rotated throughmore than 90° (120°, 170°). In this context, it is proven expedient forthe cylinder crankcase to be rotated as slowly as possible. Inparticular, the movement into this tilted position should last at leastfive seconds. It is preferable for at most the time which can be madeavailable by the cycle time of the processing line to be used for thistilting. It is expedient for the cylinder crankcase even to be rotatedthrough one full revolution about its longitudinal axis. During thistilting, inter alia the blasting fluid is at least in part removed in asimple way from the cylinder bores and in particular from desiredrecesses or undercuts and also recesses and/or undercuts which are alsodesired for the bonding of the subsequent coating and which were formedby the roughening operation.

It is expedient for the tilting of the cylinder crankcase to take placeduring the time in which it is being transported from the point ofremoval from the blasting machining unit into a drying processing unit.During this time, the cylinder crankcase can expediently also be actedon by compressed air which has preferably been heated to at least 50°C., particularly preferably to at least 70° C. This measure improves theremoval of the blasting fluid still further.

In the drying processing unit, the cylinder crankcase is heated after ithas been roughened, and the residual moisture is at least substantially,and optimally completely, removed. A standard furnace, the interior airof which is continuously recirculated and if appropriate also dried, canbe used for this purpose. Furthermore, within the furnace it may beexpedient to continue to blow hot air onto the cylinder crankcase.

After drying, the cylinder crankcase is transferred to a thermal coatingprocessing unit, inside which the cylinder bores are coated in order toform what will subsequently be the cylinder bearing surfaces. Thethermal coating processing unit, like the blasting processing unit,preferably likewise has a turntable with at least two receptacles, sothat, in this case too, simultaneous loading of this processing unit inthe region of coating lances and removal and/or loading of a receptacleis possible. Alternatively, this can also be realized by linear drivesor other standard production tools of this type.

It is preferable for the cylinder crankcase to be provided with at leastone spraying template, which is designed as a piece of tube andtherefore in hollow-cylindrical form and the clear width of which isgreater than the clear width of a cylinder bore, in the region of thecoating processing unit. The axial length of this spraying templateapproximately corresponds to the width of the thermal spraying jet, i.e.approx. 20 to 30 mm. The spraying template is preferably fitted outsidethe region of the coating processing unit in which a coating lance isarranged. As a result, in the case of a spraying template which hasalready been used, this template can be checked and if necessary removedin good time, for example if it is excessively soiled and/or the coatingmaterial is thought to have low adhesion, without involving significantintervention in the actual production sequence. It is expedient for thespraying template to be put or placed in a defined position on thecylinder head sealing surface in the region of the outer receptacle ofthe coating unit and fixed there. In this case, a single tubularspraying template is provided for a cylinder bore; it is possible toprovide at least a single cylinder bore, but also a plurality of or allof the cylinder bores, of a cylinder crankcase with an associatedtubular, hollow-cylindrical spraying template. In this case, apreferably continuous circular ring is formed between the inner wall ofthe spraying template and the cylinder crankcase in the region of thecylinder bore shielded by the spraying template. The thickness of thecircular ring is at most 1 cm and is preferably between 0.3 and 0.7,particularly preferably approximately 0.5 mm.

The cylinder crankcase, which has now preferably been provided with ahollow-cylindrical spraying template similar to a piece of tube on thecylinder head sealing surface and still has an oversized dimension ofpreferably between 0.3 and 0.7 mm, particularly preferably between 0.4and 0.5 mm, is introduced into an inner region of the coating processingunit, in which the coating of the walls of the cylinder bores is to becarried out by a thermal spraying process. The cylinder crankcase, whichis held at a defined position with a spraying template arranged in adefined position on it, is transported under a coating lance, which isconfigured such that it can rotate about its longitudinal axis.

Furthermore, if only a single hollow-cylindrical spraying template isbeing used, the cylinder crankcase may likewise be configured such thatit can rotate about this axis, the axis then being aligned with the axisof the individual cylinder bore which is to be coated. When adopting aprocedure of this nature, it is advantageous if in each case only asingle cylinder bore of a line of cylinders is thermally coated.

For this purpose—as also in the other cases—it is possible for anindividual hollow-cylindrical, tube-like spraying template to beprovided for each individual cylinder bore or for a plurality ofcylinder bores or for all the cylinder bores; the spraying template mayfor its part once again be arranged on a base plate.

It is preferable for the coating lance to be started outside thecylinder bore, in order to rule out transient initial effects. In thiscase, the spray jet may, for example, be directed onto the inner surfaceof the spraying template, in order in particular to reduce soiling ofthe installation. After an initial running time, the coating lance ismoved into the cylinder bore, and the coating is applied in a desiredminimum thickness in accordance with a predeterminable working sequence.During the application of the coating, it is expedient for a gas,preferably an inert gas, to be passed through the cylinder bore so as topartially remove spray particles from the bore. The flow velocity inthis case is expediently between 7 and 12, preferably approximately 10m/s.

To coat a respective cylinder bore, a single cylinder bore or aplurality of cylinder bores or all the cylinder bores can be with andwithout separate retraction and refitting with spraying template

The processing station described for the coating of the cylinder boreswith a layer which has been thermally sprayed and preferably applied bymeans of an arc wire spraying process (AWS process), therefore includesa blasting processing unit and a coating processing unit. It isexpedient for each of these units to be assigned a loading station,which simultaneously forms a removal station, so that the units can beloaded with cylinder crankcases for the respective working step andfinished cylinder crankcases can be removed again at the same station.The blasting and coating processing units are also assigned a dryprocessing unit, in which the cylinder crankcase is heated after theblasting operation and the blasting fluid is at least substantiallyremoved.

After the cylinder bore has been coated, the cylinder crankcase isremoved from the coating processing unit and transferred to the further,chip-forming processing operation. Here, the sprayed C, i.e. thecylinder barrel, preferably cylinder bore, is rough-honed, a bevel isintroduced in the region of the cylinder head sealing surface, thecylinder head sealing surface is milled to its final dimension,preferably by means of disposable cutting tool tips, and the cylinderbarrels are finish-honed to their final dimension in one or more steps.Apart from the rough-honing and finish-honing, which at least have tofollow one another in terms of time, these machining working steps canin principle be carried out in any desired order.

It is appropriate, however, for the bevel to be introduced after therough-honing, since in this case the finished cylinder bearing surfaceis no longer soiled or is only slightly soiled. The same also applies tothe milling of the cylinder head sealing surface to its final dimension.It is expedient for the bevel to be formed in such a way, in terms ofits inclination and depth of introduction, that it has no sprayedmaterial, but rather only cast material, at the subsequent transitionbetween the bevel and the cylinder head sealing surface which has beenmachined to its final dimension. It is therefore expedient for the bevelto be formed after the rough-honing and before the finish-machining ofthe cylinder head sealing surface and of the cylinder barrel. On accountof this sequence, the finished cylinder bearing surface is no longersoiled or is only slightly soiled, and furthermore the bonding of thesprayed material is improved, since it is no longer at risk, for exampleby being lifted off by means of a cutting edge, from the face-milling ofthe cylinder head sealing surface to its final dimension. With all theactions which have been mentioned and also those which are yet to bedescribed below, it is also expedient for the cutting edges of therespective machining tools to engage in the material which is to beremoved from the outside, i.e. approximately parallel to the surfaceorthogonal. This at least reduces or even altogether prevents detachmentof a material as a result of the cutting edge engaging from below withthe material subsequently being lifted off by the cutting edge.

It is preferable for a cone (countersinking drill, milling cutter or thelike) mounted in universally jointed fashion to be used to introduce theinsertion bevel, the cone having, at its introduction end side, a guidepin, the external effective diameter of which is selected in such amanner that in terms of the machining tolerances it corresponds at mostto the smallest clear width of the coated cylinder bore.

The guide pin is designed as a honing head, the cutting edges of whichare matched to the final dimension of the cylinder bearing surfaces. Itis preferable for the honing head to have cutting edges which can movein the radial direction and which can be locked in the at-reset positionand in the working position. This allows the introduction of the beveland the honing to be carried out in a single operation within oneprocessing station.

It is expedient for the guide pin to be placed against the cylinderbore, oriented at an inclination with respect to the longitudinal axisof the latter in the region of the subsequent insertion bevel, andthereby aligned. After floating and/or vibrating and/or shakingalignment, the guide pin is oriented axially parallel to, and preferablyaligned with, the longitudinal axis of the cylinder bore. After orduring the axial orientation of the insertion pin, the latter issimultaneously lowered at least part way into the cylinder bore.

As in the region of the cylinder head sealing surface, inter alia toimprove the bonding of the sprayed material, it is expedient for thecoated cylinder bore of the cylinder crankcase to be provided with anend bevel in the region of the crankshaft outlet side. The end bevel isdesigned in such a manner that there is no coating material, but ratheronly the cast or base material, at the transition from the end bevel tothe crankshaft space. After the end bevel has been introduced, coatingmaterial which has been deposited during the thermal spraying is removedat least partially from the crankshaft-side part of the cylindercrankcase, i.e. from the crankshaft space. The coating material isremoved by a jet, preferably a liquid jet mixed with solid particlesand/or a water jet, which is operated with a pressure of between 300 and1000 bar, preferably between 300 and 600 bar. Between 1 and 5% by volumeof cleaning agent and/or preservative are added to the jet. Therefore,the same fluid which was already used during the roughening operationcan be used as blasting fluid for cleaning the crankshaft space.However, the difference is that a significantly lower pressure is usedin this case. The material which continues to adhere to the walls of thecrankshaft space after this pressurized-jet cleaning can remain theresince, as tests have proven, it does not become detached even underextremely high loads. In this case too, to avoid unnecessary soiling ofthe cylinder bearing surface, it is expedient for the cylinder bore onlyto be machined to its final dimension after the end bevel has beenintroduced. Furthermore, it is also expedient for the machining of thecylinder bore to its final dimension only to be carried out after thefinish-machining of the crankshaft space.

In the same way as for introduction of the insertion bevel, a circularmilling cutter can be used to introduce the end bevel. It is expedientfor a guide pin, the external effective diameter of which is selected insuch a manner that in terms of the machining tolerances it correspondsat most to the smallest clear width of the coated cylinder bore, isexpediently arranged at the introduction-side end of this circularmilling cutter. The further formation and expedient procedures can beinferred from what has already been described above.

Alternatively, it is possible for a cone mounted in universally jointedfashion to be used to introduce the end bevel in the same way as for theintroduction of the insertion bevel. It is expedient for a guide pin,the external effective diameter of which is selected in such a mannerthat in terms of the machining tolerances it corresponds at most to thesmallest clear width of the coated cylinder bore, to be arranged at theintroduction-side end of this cone. The further formation andadvantageous procedures can be discerned from what has already beendescribed.

As has already been mentioned, it is expedient to ensure that duringchip-forming machining of the insertion bevel and/or of the end beveland/or of the cylinder head sealing surface and/or of the crankshaftspace and/or of the cylinder bore, the respective machining tool isguided in such a manner that the respective cutting edges penetrate intothe layer material which is to be removed from the outside.

During the cleaning/removal of coating material from the crankshaftspace, it is expedient for the cylinder to be covered. For this purpose,a ram is introduced into the cylinder or moved onto the end bevel. It ispreferable for the ram to be placed against the end bevel in such amanner as to form a circumferential and/or end seal, and preferably forthe ram to form a sealing closure at the end bevel with the aid of aseal.

In engines with cylinders arranged in a number of lines (for example Vor W engines), to prevent the introduction of spray material it isexpedient for the individual lines to be shielded from one another inthe region of the crankshaft space at least during the thermal coatingby the introduction of a shielding template. For this purpose, theshielding template preferably has an elastomer layer which is arrangedbetween two metal sheets and which can be placed against the walls ofthe crankshaft space in the region between two rows. In this case, it isexpedient for both the metal sheets and the elastomer layer to be of ashape which is the negative of the contour to be applied. It ispreferable for the metal sheets, when the shielding template is put inplace, to be at a distance from the wall, whereas the sealing elastomerof the elastomer layer bears against the wall.

Further expedient configurations of the invention are defined in theclaims. Moreover, the invention is explained in more detail on the basisof exemplary embodiments illustrated in the figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a flow diagram of the overall process,

FIG. 2 shows a diagram illustrating a possible processing station fromat least the roughening to the coating,

FIGS. 3-9 show various flow diagrams for the chip-formingfinish-machining of a coated cylinder crankcase,

FIG. 10 shows a cylinder crankcase with baffle surfaces fitted in theregion of its cylinder head sealing surface,

FIG. 11 shows a cylinder crankcase with a spraying template fitted inthe region of its cylinder head sealing surface,

FIG. 12 shows a cone for introduction of a bevel,

FIG. 13 shows a cylinder head sealing surface during the chip-formingmachining,

FIG. 14 shows a cylinder bore immediately after coating,

FIG. 15 shows a sprayed cylinder bore with insertion bevel and cylinderhead sealing surface with an oversized dimension,

FIG. 16 shows a sprayed cylinder bore with insertion bevel and cylinderhead sealing surface at its final dimension,

FIG. 17 shows a section through a coated cylinder bore of a cylindercrankcase with adjoining crankshaft space,

FIG. 18 shows a coated cylinder bore in the region of its end bevel witha sealing ram fitted,

FIG. 19 shows a shielding template for V engines, and

FIG. 20 shows the fitting of the shielding template in the region of thecrankshaft space between two cylinder lines of a V engine.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a basic sequence of a process for producing cylindercrankcases with thermally sprayed cylinder barrels. According to thisdiagram, in a first processing station 1 the blank for the cylindercrankcase 8 is cast and if appropriate also initially processed in aprocessing unit (not shown) of this processing station. The preliminaryprocessing may in this case involve the removal of slag, castingresidues and also face-milling of the cylinder head sealing surface 14to an oversized dimension.

After this first processing station 1, the cylinder crankcase 8 istransferred to a second processing station 2, in which it is, forexample, cleaned and degreased, and the walls of the cylinder bores 10are machined and roughened in regions. For this purpose, the secondprocessing station 2 may have an individual processing unit for each ofthese working steps or may also have processing units which carry out anumber of working steps or complement one another. In particular, inthis context reference should be made once again to the abovementionedmultiple action of, for example, a water jet at high pressure mixed withcorrosion-prevention agents and/or cleaning agents which are in liquidform or dissolved in the water, this water jet simultaneously havingcleaning, degreasing, machining and roughening actions.

After this pre-treatment, the pre-treated cylinder crankcase 8 istransferred to a third processing station 3, in which the cylinder bores10, and preferably, beyond the axial ends of the cylinder bores 10, inregions also the cylinder head sealing surface 14 and the crankshaftspace 55 are coated in the known way, in particular thermally coated.

After the coating of the cylinder bores 10, the cylinder crankcase whichhas been provided with the sprayed cylinder barrels is transferred to afourth processing station 4, in which it is machined, by chip-formingmachining, to its final dimensions. In this fourth processing station 4or subsequent to it, it is also possible for the crankshaft space 55 tohave relatively loose spraying residues from the thermal coating removedfrom it by means of the abovementioned high-pressure cleaning.

FIG. 2 shows a more detailed illustration combining the processing unitsof the second processing station 2 and the third processing station 3.The configuration shown in FIG. 2 comprises a blasting processing unitwith a blasting processing chamber 21 and associated turntable 22, adrying processing unit 6, a compressed air unit 7, a multi-axisindustrial robot 5 for loading and removing the various processing unitsand a coating processing unit with coating chamber 31 and associatedturntable 32. The turntables 22 and 32 each have at least tworeceptacles 23, 24 and 33, 34, on which a cylinder crankcase 8 can beplaced and from which it can be removed.

In the blasting chamber 21, the cylinder bores 10, which have previouslybeen provided with baffle surfaces 11 for the fluid jet expelled fromthe nozzles of the blasting lances, are prepared in the mannermentioned, i.e. are cleaned, degreased, machined and roughened. Then,they are moved out of the blasting chamber 21 by means of the turntable22, while at the same time the next cylinder crankcase 8 is introducedinto the blasting chamber 21. The pre-treated cylinder crankcase 8 istransported by means of the industrial robot 5 to the drying processingunit 6, during which operation it is expediently rotated slowly aboutits own longitudinal axis and exposed to warmed or heated compressed airby means of the compressed air unit 7. Previously, thehollow-cylindrical baffle surfaces 11, similar to pieces of tubes, havealso been removed from the cylinder head sealing surface 14 of thecylinder crankcase 8.

The rotation of the cylinder crankcase 8 and the application ofcompressed air advantageously serve to at least partially remove theblasting fluid, preferably from the recesses and undercuts of theroughened walls of the cylinder bores 10. Blasting fluid which stillremains is removed in the drying processing unit 6. The dried cylindercrankcase 8 is placed onto a free receptacle 34 of the turntable 32 ofthe coating processing unit, provided with spraying templates 12 andintroduced into the coating chamber 31, where it is coated in the knownway.

FIGS. 3 to 9 illustrate various flow diagrams involved in thechip-forming finish-machining of the coated cylinder crankcase.

In accordance with FIG. 3, first of all the insertion bevel 54 is formed(410) at the bores of the sprayed cylinder crankcase 8, then thecylinder head sealing surface 14 is finish-machined (420), and then thecylinder bore 10 is finish-machined (430) in one or more steps. In thiscontext, it is favorable that the finished cylinder bearing surfaces 53at least require no further significant cleaning.

In accordance with FIG. 4, first of all the insertion bevel 54 is formed(410) at the bores of the sprayed cylinder crankcase 8, then thecylinder bores 10 are finish-machined (430) in one or more steps, andthen the cylinder head sealing surface 14 is finish-machined (420). Inthis case, the finished cylinder bearing surfaces 53 still require finalcleaning.

In accordance with FIG. 5, first of all the cylinder bores 10 arefinish-machined (430) in one or more steps, then firstly the insertionbevel 54 is formed (410) at the bores 10 of the sprayed cylindercrankcase 8, and thereafter the cylinder head sealing surface 14 isfinish-machined (420). In this case, the finished cylinder bearingsurfaces 53 likewise still require final cleaning.

In accordance with FIG. 6, first of all the insertion bevel 54 is formed(410) at the bores 10 of the sprayed cylinder crankcase 8, then thecylinder bores 10 are rough-machined (431), then the cylinder headsealing surface 14 is finish-machined (420) and then the cylinder bores10 are finish-machined (432). In this case, the finished cylinderbearing surfaces 53 at least require no significant further cleaning.

In accordance with FIG. 7, first of all the insertion bevel 54 is formed(410) at the bores 10 of the sprayed cylinder crankcase 8, then thecylinder bores 10 are rough-machined (431), then the cylinder bores 10are finish-machined (432), and then the cylinder head sealing surface 14is finish-machined (420). In this case, the finished cylinder bearingsurfaces 53 likewise still require final cleaning.

In accordance with FIG. 8, first of all the cylinder bores 10 arerough-machined (431), then the insertion bevel 54 is formed (410) at thebores 10 of the sprayed cylinder crankcase 8, then the cylinder headsealing surface 14 is finish-machined (420) and then the cylinder bores10 are finish-machined (432). In this case, the finished cylinderbearing surfaces 53 at least require no further significant cleaning.

In accordance with FIG. 9, first of all the cylinder bores 10 arerough-machined (431), then the insertion bevel 54 is formed (410) at thebores 10 of the sprayed cylinder crankcase 8, then the cylinder bores 10are finish-machined (432), and then the cylinder head sealing surface 14is finish-machined (420). In this case, the finished cylinder bearingsurfaces 53 likewise still require final cleaning.

In all the sequences illustrated in FIGS. 3 to 9, the abovementionedworking steps relating to the introduction of the crankshaft-side endbevel 56 of the cylinder bores 10 are preferably possible in a simplemanner by means of a conically designed countersinking or circularmilling cutter and the finish-machining of the crankshaft space 55. Inparticular, it is expedient for the finish-machining of the crankshaftspace 55 to be carried out before the finish-machining of the cylinderbearing surfaces 53 or, with the cylinder bore 10 shielded, after thefinish-machining of the cylinder bearing surfaces 53.

FIG. 10 illustrates a portion of a cylinder crankcase 8 of afour-cylinder in-line engine with a base plate 9, on which two bafflesurfaces 11 are arranged, arranged on its cylinder head sealing surface14. The base plate 9 in this case covers, counting from the left, thesecond and fourth cylinder bores 10, whereas the baffle surfaces 11secured to it, which are of hollow-cylindrical design similar to piecesof tube, are arranged above the first and third cylinder bores 10. Onaccount of the hollow-cylindrical design of the baffle surfaces 11,blasting lances can be introduced through them into the correspondingcylinder bores 10. On account of the baffle surfaces 11 being designedsimilar to pieces of tube, i.e. on account of the axial extent of thebaffle surfaces being at least as great as the opening width of theimpinging jet at this location, the baffle surfaces can preferably alsobe placed on the cylinder head sealing surface 14 without a base plate9, in which case the cylinder bores 10 which are not to be processed atthat time are still shielded. Furthermore, in this case the two blastinglances are also protected from each other's fluid jets, since the bafflesurfaces 11 prevent these jets from widening out.

FIG. 11 illustrates a portion of a cylinder crankcase 8 of an in-lineengine with a spraying template 12 arranged on its cylinder head sealingsurface 14. The spraying template 12, which is arranged and fixed on thecylinder head sealing surface 14 concentrically with respect to thecylinder bore 10, has an opening width which is greater than the clearwidth of the cylinder bore 10. As a result, a circular ring 13 of thecylinder head sealing surface 14 between the cylinder bore 10 and thespraying template 12 remains uncovered. The axial extent of the sprayingtemplate 12 is in this case greater than the opening width of a jet ofmaterial which is sprayed onto it and has previously been melted and/orexternally fused, so that when using spraying templates 12 of this type,the cylinder bores 10 which are not to be coated at that particulartime, as well as the outer-side regions of the cylinder head sealingsurface 14, are at least substantially shielded and thereby protectedfrom the material jet from a coating lance.

FIG. 12 illustrates a tool for introducing a bevel, in particular aninsertion bevel 54 or end bevel 56, in a cylinder bore 10 with sprayedcylinder bearing surface 53, the bevel including an angle of between 5and 15° with the cylinder axis 19. The tool has a cone 15, which can beused to countersink the bevel, in particular the insertion bevel 54.

To orient the cone 15, an insertion pin 16 is arranged at itsinsertion-side end. The cone 15 and the insertion pin 16, at theirengagement-side outer peripheries, have cutting edges 17 which areintended to act in such a manner as to remove material. The cuttingedges 17 of the insertion pin 16 substantially machine the coating 18,whereas the cutting edges 17 of the cone machine the coating 18 andsubsequently the base material of the cylinder crankcase 8. To orientthe cone 15 which is mounted by a universal joint, as illustrated, theinsertion pin 16 is placed obliquely onto the upper edge of the cylinderbore 10 and is slowly oriented in the direction of the cylinder axis 19by continuous, gentle shaking or vibrating movement. In the process, theinsertion pin 16 moves into the cylinder bore 10, with the cone 15 beingoriented in the same way. Once the cone 15 has been oriented and theinsertion pin 16 is at least substantially aligned with the cylinderbore axis 19, the tool is actuated, so that the coating 18 and theinsertion bevel 54 are machined in a chip-forming manner. In a preferredembodiment, the cutting edges 17 of the insertion pin 16 are arrangedradially adjustably, so that they are only extended into their radiallimit position with a chip-forming action and become active after theorientation has taken place.

FIG. 13 illustrates the machining of the cylinder head sealing surface14. In accordance with the illustration, the cylinder head sealingsurface 14 is face-milled. In the process, the milling head 50 isoperated so as to rotate in the right-hand direction or clockwise, withthe result that the milling cutter teeth 52 move into the material fromthe outside.

FIG. 14 illustrates a cylinder bore 10 immediately after the coatingoperation. The spraying template 12 is still on the cylinder headsealing surface 14. The circular ring 13 arranged between the sprayingtemplate 12 and the upper cylinder bore opening is covered with aprotruding edge coating 51 of coating material. The walls of thecylinder bore 10 are completely covered with the coating 18 of coatingmaterial.

As illustrated in FIG. 15, an insertion bevel 54 is introduced into theupper cylinder bore 10 and its coating 18, in particular by milling.After this bevel has been introduced, the cylinder head sealing surface14 may still include parts of the edge coating 51. However, as a resultof the formation of the insertion bevel, the coating 18 is no longer indirect contact with the cylinder head sealing surface 14. Rather, onlythe casting material, i.e. the base material, of the cylinder crankcase8 is still to be found at the transition to the cylinder head sealingsurface 14.

Next, as illustrated in FIG. 16, the oversized dimension of the cylinderhead sealing surface 14 is removed, with the result that, inter alia,the edge coating 51 is also removed in a simple way. The depth ofintroduction and the setting angle of the cone 15 which forms theinsertion bevel 54 are selected in such a manner that even after removalof the oversized dimension the coating 18 is no longer in direct contactwith the cylinder head sealing surface 14. This ensures, in particularduring the face-milling of the cylinder head sealing surface 14, thatthe coating is not endangered as a result. In particular, there is noweakening of the bonding in the region of the transition to the wall ofthe cylinder bore 10, as occurs, for example, as a result of the coating18 being lifted off or flaking off at a microscopic level on account ofthe action of a cutting edge 17, in particular a milling cutter tooth52.

FIG. 17 illustrates this state of affairs with reference to the lowerbevel of the cylinder bore 10, i.e. the end bevel 56. In this case too,after introduction of the end bevel 56, there is no longer any coating18 at the transition from the cylinder which has not yet beenfinish-machined and from the finish-machined cylinder which includes thefinished cylinder bearing surfaces 53 into the crankshaft space 55.

FIG. 18 illustrates a sealing ram 57 which has been pulled into thecylinder from below, i.e. from the direction of the crankshaft space 55.On the direction on which it is pulled in, the sealing ram 57 has ashank, the external diameter of which is smaller than the clear width ofthe coated cylinder bore 10. At its lower end region, the sealing ram 57has an encircling groove in which a sealing elastomer, in particular asealing ring 58, is arranged. Below this groove, the external diameterof the sealing ram 57 is larger than the clear width of the coatingcylinder bore 10, and consequently the sealing ring 58 bears in asealing manner against the end bevel 56. By this measure it is possible,inter alia, to process the crankshaft space 55, preferably to subject itto reaming and/or high-pressure cleaning by means of a water jetpreferably mixed with preservative and/or cleaning agent. Furthermore,chip-forming machining is also possible. This is particularlyadvantageous in particular in the case of cylinder bearing surfaces 53which have already been finish-machined.

When coating cylinder bores 10 of multi-line engines, such as V and/or Wengines, disruptive deposits of material are constantly formed incylinder bores 10 which belong to a cylinder line which is parallel tothe line currently being processed. In this respect, it is expedient fora shielding template 59, as illustrated by way of example in FIG. 19, tobe arranged between the two cylinder lines (cf. FIG. 20) on thecrankshaft side.

The shielding template 59 has two outer metal stabilizing plates 60 anda sealing lip 61, preferably formed from elastomeric material, arrangedparallel to and between them. The shielding template 59 is in this caseshaped in such a way that it approximately corresponds to the negativeof the surface onto which it is placed between the two lines ofcylinders. The extent of the metal sheets 60 in the direction of thebearing surface is advantageously less than that of the sealing lip 61,so that good bearing contact is possible.

The shielding template 59 is of toothed design on the bearing side. Thisallows the toothed base 63 to be placed in the region of the balancingweights of the crankshaft and the teeth to be placed in the region ofthe crankshaft bearing arrangement.

The foregoing disclosure has been set forth merely to illustrate theinvention and is not intended to be limiting. Since modifications of thedisclosed embodiments incorporating the spirit and substance of theinvention may occur to persons skilled in the art, the invention shouldbe construed to include everything within the scope of the appendedclaims and equivalents thereof.

1. A process for processing cylinder crankcases having sprayed cylinderbarrels, in which process a cylinder crankcase is cast, those surfacesof the subsequent cylinder barrels which are to be thermally coated areroughened, and the cylinder barrels are remachined to their finaldimensions, comprising: coating the cylinder barrels by a thermalspraying process, and at least partially removing the coating materialfrom a crankshaft side part of the cylinder crankcase after coating thecylinder barrels.
 2. The process as claimed in claim 1, wherein thecoating material is removed by a jet.
 3. The process as claimed in claim2, wherein the jet is operated with a pressure of between 300 and 2000bar.
 4. The process as claimed in claim 2, wherein between 1 and 5% byvolume of cleaning agent, preservative, or cleaning agent andpreservative are added to the jet.
 5. The process as claimed in claim 2,wherein, during removal of the coating material, the cylinder is coveredwith respect to a crankshaft space by way of a ram introduced into thecylinder or moved onto an end bevel, the ram being placed against theend bevel in such a manner as to form a seal.
 6. The process as claimedin claim 1, wherein machining of the cylinder barrels to their finaldimensions is carried out after a crankshaft space has beenfinish-machined.
 7. The process as claimed in claim 1, wherein thecoated cylinder barrels are pre-processed, a crankshaft space issubsequently finish-machined, and, next, the cylinder barrels aremachined to final dimensions in one or more steps.
 8. The process asclaimed in claim 2, wherein the jet comprises a liquid.
 9. The processas claimed in claim 2, wherein the jet comprises a liquid mixed withsolid particles.
 10. The process as claimed in claim 2, wherein the jetcomprises water.
 11. The process as claimed in claim 9, wherein the jetfurther comprises water.
 12. The process as claimed in claim 9, whereinthe liquid is water.
 13. The process as claimed in claim 8, wherein theliquid is water.
 14. The process as claimed in claim 3, wherein thepressure is between 300 and 800 bar.
 15. The process as claimed in claim5, wherein said seal aids in forming a sealing closure.
 16. A cylindercrankcase processed in accordance with the process of claim 1.